Operating Manual - Stanmech Technologies Inc.
Contents
1. OPERATING INSTRUCTIONS LEISTER Astro Automatic Wedge Welding Machine AN Please read operating instructions carefully before use Ll and keep it for further reference APPLICATION The LEISTER Astro is an automatic wedge welding machine for overlap welding of geomembrane liners in earthwork and civil engineering e Thermoplastic geomembrane liners e Type of seam High density polyethylene PE HD Welding seams are pro Low density polyethylene PE LD duced in accordance Chlorinated polyethylene PE C with DVS 2225 part Polypropylene PP Other dimensions are pos sible on request DVS German Welding Society for welding LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 7474 Fax 41 41 6627416 www leister com sales leister com N WARNING Danger Unplug the tool before opening it as live com ponents and connections are exposed Incorrect use of the hot wedge tool can present a fire and explosion hazard especially near combustible materials and explosive gases Do not touch the element housing and wedge when hot as they can cause burns Allow the tool to cool down Do not point the hot air flow in the direction of people or animals Connect the tool to a socket outlet with protective earth conductor Any interruption of the protective earth conductor within or outside the tool is danger ous Use only extensions cables with a protective earth conductor o pe N CAUTION The voltage2. 20 0 420 USB wo No File name e A file name consisting of the current date month and day and the file number will be created automatically when recording is started Example 0309 002 09 March second recording 5 iuret 3 2 20 1000 e The file number increases automatically every time it is saved 2 420 gt 9 The number begins again at 001 every day 3 0 00 Presettings e To set date edit client text or display of operating hours counter By pressing keys l and at the same time the following display appears YH Date Text gt x Show Timer M 30 H Set Date SEU aoa 2 10 390 210 Show Text gt Changes automatically to operating mode after 3 seconds COMPANY Time 14M07 43 M Edit H OK Date 16 02 10 A or key H sEnter edit value before the cursor HE or key e key y en H move cursor to next value l H key H key H k M key Existing text is Hl a M return to operating mode accepted symbo Return to M key l operating mode IM back to previous symbol Finish Enter a space as the last character Confirm with the H key The text may be a maximum of 16 characters long FIRMA XY Text Ok H 0k 12 Default settings Setting the start value of the joining force for the recording The joining force which is t
3. should be about 1 mm e Tighten the hexagon cap screw of the front guide roller 18 Cross section diagram of hot wedge system CHANGEOVER OF UPPER DRIVE PRESSURE ROLLER LEISTER Astro The LEISTER Astro is suitable to manufacture overlap welded seams in different fields of applications They differ in the width of the welded seam as well as the width of the test channel Also welded seams without test channel can be manufactured In order to implement these different overlap seams the appro priate drive pressure rollers have to be installed 1 Countersunk screw M3x6 7 Shaft 8x118 5 2 Protection sheet swivel head 8 Shaft retaining ring 3 Socket head screw M4x8 9 Distance disk 20x32x0 5 4 Washer 4 2x25 10 Drive pressure roller 5 Slide roller 11 Woodruff key 5x6 5 6 Set screw M5x12 12 Upper drive shaft complete Dismantling of the drive pressure rollers sequence 1 12 Assembly of the drive pressure rollers reverse order 12 1 CHANGEOVER OF LOWER DRIVE PRESSURE ROLLER LEISTER Astro 1 Countersunk screw M5x 16 2 Clamp disk 3 Drive Pressure roller 4 Distance disk 20x32x0 5 Dismantling of the drive pressure rollers sequence 1 4 Assembly of the drive pressure rollers reverse 4 1 TRAINING LEISTER Process Technologies and their authorised Service Centres offer free welding courses and training ACCESSORIES e Only LEISTER accessories should be used MAINTENANCE e Check m
4. Check the welded seam wash seam thickness reduction As required adjust the welding speed with El keys on keyboard 6 e The automatic welding machine is guided along the overlap with the carrying handle guide handle 12 so that the frontal width of the overlap is kept within The 22mm zone see illustration B Illustration B Se gt ZZZ z KEE s Max frontal width of Dim of pressure roller 50mm p Dim of pressure roller 45mm P7 X yj 24 5 mr End of welding process e Release the tension lever 9 1 cm before the end of the welded seam e Switch off the drive motor with key IM on the keyboard 6 Switch off the heat ing by pressing the Hana Flkeys on the keyboard 6 simultaneously 8 ADJUSTING THE HOT WEDGE LEISTER Astro Adjusting of the guide rollers for the requested material thickness e Engage the automatic wedge welding machine on the geomembrane liner or film to be welded e Stretch the lever 9 e Loosen the hexagon cap screw of the rear guide roller 19 e The distance between the hot wedge 8 and the rear guide roller 19 should be the thickness of the material and the sharp tongue of the wedge should lie centrically to the pressure rollers 20 21 e Tighten the hexagon cop screw of the rear guide roller 19 e Loosen the hexagon cap screw of the front guide roller 18 e The distance between hot wedge 8 and front guide roller 18
5. rating stated on the tool should correspond to the mains voltage For personal protection we strongly recommend the tool be connected to an RCCB Residual Current Circuit Breaker before using it on construction sites The tool must be operated under supervision Radiant heat from the hot wedge can ignite flammable mate rials Protect the tool from damp and wet DOGG APPROVAL MARKS TECHNICAL DATA Protection class I CCA certified Voltage V 120 200 230 y mains voltage is Frequency Hz 50 60 not reversible Power consumption Ww 1800 Temperature C F max 420 788 Welding pressure N Ibs max 1500 337 Drive m min feet 0 8 5 0 2 6 16 5 Overlap width mm Inch max 150 5 9 Thickness of material mm mil 1 5 3 0 60 120 Noise emission level Lpa dB 70 Size LxWxH mm 475 x 355 x 315 with carrying handle guide handle 12 Weight kg lbs 23 50 2 FUNCTIONAL DESCRIPTION LEISTER Astro Heating system The hot air temperature is steplessly adjustable and eletro nically controlled It is a floating hot wedge Cross section diagram of hot wedge system y Pinch roller Upper geomem brane liner Upper drive pressure roller Welding direction gt illa Er Fastening screw for hot wedge Lower drive pressure roller Lower geomem brane liner Rear guide Front guide roller roller e Welding pressure infinitely variable steplessiy adjustable The welding pres
6. sure is transmitted via a toggle lever to the pressure rollers The swivel head guarantees the equalization of the pressure to both welded sections C and D as well as on a welded seam without test channel This allows T joints to be welded easily During the welding process the pres sure adjusts itself linearly to the change in material thickness of the geo membrane liners Cross sectional diagram of an overlap weld Seam thickness reduction A B Thickness of the upper and lower membrane Thickness of the welded seam Welded section 1 Welded section 2 Test channel moOowr e Drive The welding speed is adjustable and electronically controlled in steps of 0 1 m min feet Digital display of SET and ACTUAL values The power trans mission works through a three stage planetary gear DESCRIPTION OF MACHINE LEISTER Astro Frontal view DESCRIPTION OF MACHINE 1 Mains cable 14 2 Cable clip 15 3 Housing of electronics 16 4 Main switch 17 5 Display 18 6 Keyboard 19 7 Motor Drive 20 8 Hot wedge 21 9 Lever 22 10 Adjustment screw for welding pressure 23 11 Locking spring of adjustment screw 24 12 Carrying handle Guide handle 25 13 Front wheel WELDING PARAMETER N Welding pressure Illustration A 1500 1375 1250 1125 1000 875 750 625 500 375 250 125 12345612
7. 3456 max welding pressure 1500 N LEISTER Astro Back wheel Foil guide Cable conduit for hot wedge Pinch roller Front guide roller Rear guide roller Lower drive pressure roller Upper drive pressure roller Adjustment screw for swivel head Chain guard of lower part Chain guard of tension arm Chain guard of gear case LEISTER Astro Welding pressure 109 and position the automatic welding machine onto the material to be wel ded Insert the two geomem branes liners or films about 5mm at the back of the machine Pull the lever 9 The hot wedge is automat ically pushed forward Push and hold down the lockin spring 11 Turn the adjust ment screw for welding pres sure 10 until the drive pres sure rollers 20 21 slightl touch the material to be wel ded Let go the locking spring 11 and release the tension of the lever 9 Keep pushing the locking Seng of the adjustment screw 11 Adjust the welding pres sure by turning the correspon ding adjustment screw 10 according to Illustration A and let go the locking spring 11 at the requested welding pres sure Warning If the maximum welding pres sure of 1500N is exceeded mechanical damage may occur 2 WELDING PARAMETERS LEISTER Astro Welding temperature EN Set the welding temperature with the Hl Iz keys The temperature is dependent on the material and the ambient temperature The in put SET value will be shown on the displa
8. SET value Voltage display ACTUAL value Heating Drive active lt Overload indication P Main Switch 4 ON LEISTER Astro 1 3 5 000 3400 230V eco DO 2 4 1 3 5 eeu 400 230V 46 60 2 4 6 ecus 400 esov n 45 Check the welding process and identify faults by means of the display of power consumption Display 4 Heating reason for fault after heating up time 100 e mains under voltage Display 2 Drive reason for fault 100 100 or 100 or 100 or 100 or MAMA e mains under voltage e overlap of the geomembrane liner too wide e dirt on the drive rollers 20 21 e max welding pressure 1500 N has been exceeded e high welding speed with large sudden overload ie anchoring trench T joints If malfunction does not disappear contact service center AAA qq WELDING LEISTER Astro Welding procedure e Check Drive Pressure rollers 20 21 as well as the hot wedge 8 must be clean before engaging into the geomembrane liner or film Cable length Cable guide e Adjust welding parameters see page 5 6 e The welding temperature must be achieved e Guide and position the automatic welding machine into the over lapped geomembrane liner or film e Switch on drive motor with Mj key on keyboard 6 e Pull the lever 9 Beginning of welding process e
9. ains cable 1 and plug for electrical and mechanical damage e Clean hot wedge 8 with a copper brush e Clean drive and pressure rollers 20 21 with a wire brush e Treat chain 22 with a suitable spray as required chain guard 23 24 e Check whether rollers 13 14 17 18 19 are running smoothly SERVICE AND REPAIR e The tool should be checked by an authorized Service Center if the following message appears on the display 5 maintenance servicing e Repairs have to be carried out by authorised LEISTER Service Centres only They guarantee a specialized and reliable repair service within 24 hours using original LEISTER spare parts GUARANTEE AND LIABILITY e Guarantee and liability are in accordance with the guarantee certificate as well as with the currently valid general business and sales conditions e LEISTER Process Technologies rejects any guarantee claims for tools which are not in their original condition The tools must never be altered or changed Technical data and specifications are subject to change without prior notice Your authorized Service Centre is LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 74 74 Fax 41 41 6627416 www leister com sales leister com 10 Operating instructions Translation of the original operating instructions Please read operating instructions carefully before use and keep for future reference Please keep the operating instructions t
10. lues are now recorded every 5cm Stopping the recording o Recording is stopped automatically when the drive is switched off or the clamping lever is released e f only the clamping lever is released a new file will be created automatically which will be written to when the clamping lever is reactivated The message PLEASE WAIT USB appears on the rg PLEASE WAIT USB Never remove the USB stick from the USB port while the S0 2 420 message PLEASE WAIT USB is still shown Further recordings 4 e f the drive and heating remain switched on a new file will be created and the process values will be recorded every time the clamping lever is activated e f the drive is switched off no new file will be created and there will be no recording of the process values after the clamping lever is activated e f the values are not to be recorded any more the USB stick must be removed e Check the remaining memory of the USB stick on the PC from time to time Evaluation e Insert USB stick into USB port of a computer not supplied e Start spreadsheet software not supplied Open file e Select drive drive with USB stick File type all files e Select and open the desired recorded file csv e The file opens Example of file content Full Report Client text can be edited COMPANY Number of recording file File number 0825 002 LEISTER Switzerland ASTRO Software Release 3 1A USB Serial number ASTRO Se
11. o be recorded can be set between 100 N and 500 N in 5 N increments initial Press H or M key once to return to operating mode changes automatically after 3 seconds Activating the alarm output An acoustic alarm is activated if tolerances are exceeded This alarm can be switched ON or OFF The parameters can be edited 0 0 3 2 ALARM Press M key once to return to operating mode changes automatically after 3 seconds key Alarm OFF x recording no yes ara Press M and H keys simultaneously value 200N or key Edit value 20 420 0 USB Press H key twice H set key Alarm ON Press H key once to go to recording mode selection and to set the limit values Default settings Select recording mode e Short Report Record only if parameters are outside the set limit values Long Report Recording every 5 cm Set limit values for alarm output If the effective value is outside the set limit values the acoustic alarm will be activated M key Return to operating mode changes automatically after 3 seconds Press H key three times to set the limit values Recording mode Full Report or key H Toggle between Full Report or Short Report limit setting Temp _min 400 C El 4 or key Edit values limit setting Temp _ma
12. o hand when operating the COMET hot wedge welding machine Li USB port optional e Attachment for the Leister ASTRO hot wedge welding machine Application The USB port enables the process values temperature speed and pressure to be recorded on a standard USB stick The assessment is made using spreadsheet software not supplied e g Microsoft Excel Basic information regarding the USB stick Never remove the USB stick from the USB port while saving The data will not be saved Always finish recor ding welding in accordance with the operating instructions e f a new USB stick is used this should be formatted in format FAT 32 with memory size 512 bytes Important Always test new USB sticks on the device Sometimes not all USB sticks work with the device This can depend on USB copies or on preinstalled software which wants to start up automatically for example etc Date and time e Set up or check the date and time the first time that the device is started up You can find the instructions for this under the heading Presettings diagram The date and time are powered by a battery independent of the power supply It is recommended to check its function periodically Inserting USB stick e Unscrew protective cover e Insert USB stick in the USB port e Screw the protective cover back on e USB appears at the bottom right of the machine s display Without the USB stick the mains voltage is displayed at the bottom right
13. rial number 715092 Header Date 25 08 2010 Time 16 02 16 v 2 5 m min t 380 C Recording interval intervall 5cm Start value for recording initial value 350N Alarm switched off Alarm OFF Column headings Distance Speed Temperature Force Unit cm v m min t C FIN 1 Record 0 2 5 380 1015 another record every 5cm 5 2 5 380 1015 10 2 5 380 1015 15 2 5 380 1015 20 2 5 380 1015 25 2 5 380 1015 30 2 5 380 1015 35 2 5 380 1015 40 2 5 380 1015 45 2 5 380 1015 Data 50 2 5 380 1015 55 2 5 380 1015 60 2 5 380 1015 65 2 5 380 1015 70 2 5 380 1015 75 2 5 380 1015 80 2 5 380 1015 85 2 5 380 1015 90 2 5 380 1015 95 2 5 380 1015 100 2 5 380 1015 Evaluation Short Report Header Client text can be edited Number of recording file Serial number ASTRO Recording interval Start value for recording Alarm switched on Alarm limit values Data COMPANY File number 0826 003 LEISTER Switzerland ASTRO Software Release 3 1A USB Serial number 715092 Date 26 08 2010 Time 08 02 28 v 2 7 m min 380 C intervall 5cm initial value 350N Alarm ON Limit setting Lower limit temp 350 C Upper limit temp 450 C Lower limit force 800N Upper limit force 1200N Tolerance speed 5cm Column headings Deviations from the limit values are logged only if alarm is active Distance Speed Temperature Force No limit value deviations Summary Column heading
14. s Seam length Unit Summary of the welding para meters at the end of the seam m 380 1015 1015 If a parameter is outside the set limit values this will be logged only if alarm is switched on At the end of the recording a summary of the welding is logged Compile diagram only possible with Full Report oS Select a recording Highlight columns including column headings Click on the create diagram symbol and create diagram using the wizard for more precise specifications see the Microsoft Excel help or Excel user s manual not supplied Possible representation 1200 1000 800 600 Speed m min 400 Temperature C Force N 200 Distance cm Temperature C Force N Speed m min 20 LersTER BN Your authorised Service Centre is Leister Process Technologies Galileo Strasse 10 CH 6056 Kaegiswil Switzerland Tel 44141 662 74 74 Fax 41 41 662 74 16 www leister com sales leister com 141 158 GER ENG BA USB Port 11 2010 Anhang zu BA ASTRO
15. x 450 C H limit setting Force_min 1000N H limit setting Force_max 1250N H limit setting Speed 5cm B 0 0 20 0 3 2 420 USB Display when alarm activated Display when alarm activated Speed below the limit value flashing Speed above the limit value flashing Temperature below the limit value flashing Temperature above the limit value flashing Joining force below the limit value flashing Joining force above the limit value flashing va 0 0 S u lue 3 0 gt 20 x 0 420 USB 420 x1000 420 2002 420 x1000 420 420 Tog 2002 2002 luex1000 20 420 gt 002 gt 002 Recording the process data 4 e After the presets have been entered correctly the device is ready to record e The heating and drive must be switched on in order to start a recording as per ASTRO operating instructions The message PL a A gt ys as USB PLEASE WAIT USB flashes on the display Now the file is opened and the header created e The symbol appears before the file number as soon as the file has gt 5 i 00 3 been created The welding machine is now ready for recording to start e Recording is started by activating the clamping lever As soon as the pressure exceeds the set value setting of pressure 3 2 420 1000 initial value the symbol on the display changes from to a flashing 3 2 420 002 The speed temperature and pressure va
16. y Switch on the heating by pressing the TH and keys simultaneously Heating up time approx 5 mins n cursor will blink on Healing e I gt the display I SET value setting ron nn 3010 es IE amp ON OFF uuu HOD cC3uv eei unnx _ u uu Welding Speed According on the film or geomembrane liner and the influence of the weather set the welding speed with the el keys The in put SET value will be shown on the display Drive gt A SET value setting n n 33 m oworr 220 20 230V ee0 400 WELDING LEISTER Astro Welding preparation Laying Width of overlap is about 80mm to 130mm Geomembrane liners must be clean between the overlap as well as above and below Mains supply At least 3kW generator supplied with an RCCB Cable to mains A minimum cable cross section in accordance with the table 200 230 V to 50m 3x1 0mm to 100m 3x2 5 mm 120 V to 50m 3x1 5 mm2 to 100m 3x2 5 mm WELDING Operating conditions e Connect the hot wedge welding machine to the mains e Start the machine with Main or Control Level Main Level Speed Speed lemperature Temperature aN Control Level Speed Speed Temperature Temperature Oo RON Voltage display Main Switch 4 ON ACTUAL value SET value ACTUAL value SET value ACTUAL value e ACTUAL value SET value ACTUAL value
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